Contents: Removal ⤓ Installation ⤓
Attention! To dismantle engines of all modifications, it is necessary to remove the transmission, transfer case and front propeller shaft (see subsection 9.3.6, subsection 9.1.6 and subsection 9.3.9). When dismantling the engine, apply marks of mutual orientation to the removed units and the hood, clearly mark all disconnected wires and hoses. When removing 3.0L and 3.5L engines, do not allow the temporarily disconnected air conditioner and power steering pump to hang down by the hoses. Please note that when removing the engine, you should be extremely careful, since the gaps between the engine and the body panels are small, and the unit itself has significant weight.
Disconnectable hoses and wires when removing a 4-cylinder engine
1. Throttle cable; 2. Heater hose; 3. Brake booster hose; 4. Cooling system bypass hose; 5. Cooling system hose; 6. Radiator hose; 7. Engine control system harness; 8. Air Conditioner Fluid Temperature Sensor Connector; 9. Air Conditioner Coolant Temperature Gauge Sensor Connector; 10. Vacuum hose; 11. Engine Management System Fluid Temperature Sensor Connector; 13. Oxygen sensor connector; 14. Oil pressure sensor connector; 15. Power steering pump belt; 16. Power steering pump; 17. Air conditioning compressor belt; 18. Air conditioning compressor; 19. Gasoline; 20. Generator connector; 21. Ground wire; 22. Front exhaust pipe; 23. Fuel line mounting bracket; 24. Shield; 25. Front support bolt; 26. Engine
Removal
1. Depressurize the air conditioner (if provided) at the car service.
2. Remove the hood.
3. Raise the vehicle and remove the engine shields.
4. Drain the cooling system.
5. Drain the oil from the transmission, engine, transfer case and front differential.
6. Remove the air filter.
7. Remove both fan shrouds.
8. Remove the radiator.
9. Disconnect the throttle cable.
10. Disconnect the heater, cooling system and brake booster hoses from the engine.
11. Disconnect the large multi-pin connector from the engine management system wiring.
12. Disconnect the vacuum hose and unscrew the coolant temperature gauge sensor.
13. Disconnect the wires from the oxygen sensor and the oil pressure sensor.
14. Remove the power steering pump belt by loosening the pump mounting bolts.
15. Remove the power steering pump and set it aside without disconnecting it from the line.
16. Remove the belt and air conditioning compressor. Move the unit to the side without disconnecting it from the line and secure it.
17. Disconnect the fuel hoses after decompression (on injection engines).
18. Disconnect the 3 connectors on the generator.
19. Disconnect the ground wire from the cylinder block.
20. Disconnect the exhaust pipe from the manifold and secure the pipe with a wire.
21. Disconnect all hoses from the absorber tank that lead to the engine compartment bulkhead.
22. Remove the fuel line mounting bracket on the engine.
23. Attach the hoist and lift the engine.
24. Remove the shield from the right support.
25. Loosen the bolts securing the engine mounts to the frame.
26. Carefully lift the engine and remove it from the engine compartment. Place the engine on stands (not on a pallet).
Installation
The engine is installed in reverse order. First of all, install the engine, tighten the support bolts and tighten them to 35 Nm. Replace the exhaust pipe gasket on the manifold and the mounting bolts. Tighten the radiator mounting bolts to 7 Nm. Fill with fluid, oil and start the engine. After warming up, restore fluid levels. Have your air conditioner refilled at a car service center. Adjust cable, belts, idle and ignition.